Thermal bonding conjugate fiber with excellent bulkiness and softness, and fiber formed article using the same

Abstract

A thermal bonding conjugate fiber constituted from a first component comprising a polyester resin and a second component comprising a polyolefin resin with a melting point lower than that of the polyester resin by not less than 20° C., characterized in that a post-heat treatment bulk retention rate thereof is 20% or more when calculated by the following measurement method: Bulk retention rate=(H1 (mm) / H0 (mm))×100(%) (wherein H0 is the web height when a 0.1 g / cm2 load is applied to a web with a mass per unit area of 200 g / m2; and H1 is the web height after a heat treatment for 5 min at 145° C. when a 0.1 g / cm2 load is applied to that web).

Description

TECHNICAL FIELD[0001]The present invention relates to a thermal bonding conjugate fiber, more particularly to a thermal bonding conjugate fiber with excellent bulkiness and softness for uses in absorbent articles such as diapers, napkins, pads or the like, medical hygiene supplies, daily living-related materials, general medical supplies, bedding materials, filter materials, nursing care products, and pet products or the like, and relates to a process for producing the same, and to a fiber formed article using the same.BACKGROUND ART[0002]Thermal bonding conjugate fibers can be processed by heat fusion bonding utilizing thermal energy such as hot air or a heated roll and the like, and these fibers can be widely used for hygiene supplies such as diapers, napkins, pads, etc., articles for daily living, or industrial supply materials such as filters and the like because bulkiness and softness are easily obtained thereby. Bulkiness and softness are extremely important, especially in hyg...

AI Technical Summary

Benefits of technology

[0006]An object of the present invention is to provide a thermal bonding conjugate fiber that maintains crimped form stability during thermal bonding when fabricating a nonwoven fabric therefrom, and that imparts not only bulkiness and bulk recovery to the nonwoven fabric, but also excellent softness thereto; and a fiber formed article using the same.

[0018]The thermal bonding conjugate fiber of the present invention maintains crimped form stability even during thermal bonding when producing a nonwoven fabric therefrom because the bulk retention rate is held at 20% or higher after heat treatment, thereby enabling preparation of a nonwoven fabric not only with a high level of softness but also with excellent bulkiness and bulk recovery.

Problems solved by technology

Typical means of obtaining bulkiness involve using a highly rigid resin or using a fiber with increased fineness, but in such cases the softness thereof is decreased, and the physical irritation toward the skin is increased.

On the other hand, when softness is given priority to control the irritation of the skin, a nonwoven fabric with inferior body fluid absorption results because bulkiness, and especially the cushioning effect with respect to body weight, is markedly decreased.

This process is one imparting bulkiness to the obtained nonwoven fabric by using a highly rigid resin for the core member of the conjugate fiber, but the softness thereof is unsatisfactory; moreover, the bulkiness of the nonwoven fabric obtained thereby is decreased, especially if the thermal bonding temperature is high, making it almost impossible to obtain both properties with this process.

However, when the fiber is fabricated into a nonwoven fabric, during the process of performing thermal bonding at a temperature equal to or greater than the melting point of the polyolefin, a decrease in thickness occurs due to relaxation of the crimp, shrinkage, and the like because the crimped form is not sufficiently stable with respect to heat, and it is almost impossible to obtain a bulky nonwoven fabric.

H3-21648, on the other hand, bulkiness is imparted to a nonwoven fabric by using a polyethylene or polypropylene for the latently adhesive component and a polyester for the other, and a conditioning heat treatment is performed at a preselected temperature range after drawing and crimping, and although bulkiness was superb in this case, the softness of the nonwoven fabric obtained thereby was insufficient.

In addition, because relaxation of the crimping sometimes occurs in the conditioning step of this method, the crimped form was still lacking in stability.

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